Custom Product Support Literature for the 980H Wheel Loaders that have a 331-9943 Steel Mill Arrangement {7000} Caterpillar

Custom Product Support Literature for the 980H Wheel Loaders that have a 331-9943 Steel Mill Arrangement {7000}

Usage:

980H JMS

Wheel Loader:: 980H (S/N: JMS1-UP)

Introduction

This supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for this machine. This supplement shows the custom modifications that have been made to the standard machine configuration.

Use the Service Manual and the Parts Manual available for the standard machine if the service information is not in this supplementary product support literature.

331-9943 Steel Mill Arrangement for the 980H Wheel Loaders

The 980H Wheel Loaders with the Steel Mill Arrangement are designed to reduce the effects of the heat of handling hot slag. Caterpillar wants the customer and the end user to be aware that this arrangement does not make the machine fireproof!

331-9943 Steel Mill Arrangement

This arrangement is the top-level part number for the steel mill arrangement. The part numbers that are listed below are assemblies and groups within the top-level steel mill arrangement.

222-1738 Brake Accumulator Gp

The brake accumulator is a 3.79 L (231.28 cubic inch) hydraulic brake accumulator with piston seals that have a higher temperature rating.

Note: Contact your dealer for service repair. Replacement accumulators should consist of the high temperature piston seals.

184-4740 Secondary Steering Ar

This group provides a secondary steering system.

329-6627 Steel Mill Arrangement

This steel mill arrangement includes the following assemblies and groups .

362-1143 Steering Shaft

Standard steering shaft assembly is replaced by a steering shaft that consists of a steel cover. This steel cover provides higher resistance to heat and slag than the standard plastic cover for the steering shaft.

189-8281 Insulator

Heat insulation between the batteries and the battery box. This insulation helps to reduce the heat transfer from the steel battery box to the batteries.

233-9688 Transmission Ar (Heavy-Duty)

The heavy-duty transmission utilizes 432 mm (17 inch) planetary drives for all of the gears. This transmission arrangement is beneficial for extreme operating conditions that include heavy loads and many directional changes.

246-8692 Precleaner Group (Turbine)

This precleaner group provides a taller stack and precleaner assembly.

273-5629 Override Control Gp

Multiple overrides can be found in this group. These systems are designed to provide the operator with alternate controls in an emergency situation.

Parking Brake Override - The parking brake override allows the release of the parking brake from the rear of the machine.

Transmission Override - The transmission override bypasses the standard transmission control module. The transmission override also allows the operator to shift the machine into first gear forward or first gear reverse.

Auxiliary Ignition - The auxiliary ignition provides the operator with the option of bypassing the standard ignition switch.

Note: These overrides cannot possibly address every failure mode. The overrides simply give the operator an alternative option.

Operating instructions for these overrides are included in this document.

284-2176 Loader Frame Gp

This group adds the weld studs for the Guard GP to the loader frame.

286-3807 Power Train Electronic Control Module

This software is for the control module that is used on the Steel Mill Arrangement.

289-8295 Step Gp

The 289-8295 Step Gp replaces the rear standard rubber supports for the steps with steel cable supports. These steps provide longer life in a high temperature environment.

301-2932 Front Fender Gp

These narrow steel fenders replace the standard fenders. All rubber components that could deteriorate with high temperatures are removed.

303-4010 Brake Control Conversion Ar (Parking)

The 303-4010 Brake Control Conversion Ar (Parking) provides new bearings in order to avoid locking the lever that is in the brake control group.

323-0990 Side Panel Group

The 323-0990 Side Panel Group provides steel side panels.

331-7338 Protection Ar

This group provides steel guards for the main implement valves and for the steering cylinders. A protective wrap for high temperatures is also called out for the various hydraulic lines and the electrical lines that are listed below:

189-7054 Tilt Cylinder Lines Gp (With insulation)
189-7059 Lift Cylinder Lines Gp (With insulation)
189-7090 Ride Control Lines Gp (With insulation)
189-7941 Lines Guard Gp
201-8746 Insulation Gp (Power train oil filler)
201-8747 Hydraulic Oil Lines Gp (Manual valve)
284-8611 Lines Guard Gp
284-8612 Lighting Wiring Gp
288-8798 Fuel Lines Gp
293-3876 Hydraulic Oil Cooler Lines Gp
294-5002 Diagnostic Lines Gp
298-6395 Protection Wiring Gp (With insulation)

331-7339 Guard Ar

This arrangement provides the following guards:

153-7786 Loader Frame Guard
160-9514 Front Guard
240-8591 Fuel Tank and Hydraulic Tank Guard
242-6035 Cab Guard Gp
249-2679 Tilt Cylinder Guard Group
269-9086 Window Wiper Guard Group
339-8801 Cover As (RH)
245-2952 Cover As (LH)

331-7340 Hardware Ar

This group provides added support for the transmission, which is beneficial for applications that include a high number of directional changes.

247-3027 Transmission Support
283-2173 Rear Frame Hardware Group (Steel mill)

331-7341 Cab Ar

This arrangement includes rubber mounted glass for quick replacement.

265-6753 Enclosed ROPS Cab Ar (Seal mounted glass)
290-0018 Window Gp (Heat Resistant glass)
216-0461 Insulation Gp (Parking brake control)

331-7342 Lighting Ar

This group mounts the front flood lamps and signals closer into the frame which is beneficial for operating the machine in narrow places.

282-1794 Signal Lighting Gp
293-3793 Flood Lighting Ar (With lighting guards)

201-8253 Lift Cylinder Lines Gp (With insulation)

This group provides protection for the secondary steering system.

2Q-7734 Glycol Hydraulic Arrangement

The 2Q-7734 Glycol Hydraulic Arrangement converts the hydraulic system fluid to the fire resistant water/glycol solution Ecosafe 68.

Note: The hydraulic system requires thorough flushing before installation of the fire resistant fluid.

355-2974 Oil Filter Gp

This group provides an advanced efficiency filter element for use in Steel Mill applications where ECOSAFE FR68 or FR46 oil is used. The advanced efficiency filter element should be used in place of the ultra high efficiency filter element.

349-8260 Bucket Pin Gp

This group contains a "B" pin and bearing designed for the bucket of Medium Wheel Loader steel mill machines that are working in severe applications. The pin and bearing have a special thermal treatment and a special chemical treatment. A ribbed surface has been added to the bearing in order to improve lubrication. The diameter of the pin has been reduced by 0.1 mm (0.004 inch) in order to increase clearance. This design will improve the lubrication of the assembly. The design will also make the assembly more rugged in the harsh work environment that is specific to machines in steel mill applications.

Operation of the Parking Brake Override

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Illustration 1	g01338871
Rear view of machine (A) Override switches for the parking brake and auxiliary engine shutdown

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Illustration 2	g01338889
Override switches and indicator for parking brake (B) Override switch for the parking brake (C) Override indicator for the parking brake (D) Auxiliary engine shutdown switch

Your 980H Wheel Loader comes with a parking brake system that is activated by a spring and released hydraulically. If the machine stalls, the switch for the parking brake release can be activated so the machine can be towed. The switch for the parking brake release is located in the rear grill of the machine. In order to access the switch, flip up the switch guard. Move the switch downward in order to release the parking brake. An auxiliary accumulator stores hydraulic pressure which releases the parking brake when the switch is activated.

The parking brake override also has a test mode. Move the switch upward in order to enter the test mode. The green indicator should light indicating that the system is working correctly. Test the parking brake override daily. If the green indicator lamp does not light, contact your local dealer for service. The machine should not be put back into operation until this issue is resolved. When the test is completed, make sure that the toggle switch is put back into the center position. Make sure that the guard for the switch is closed in order to protect the switch.

Note: Make sure that the parking brake override is not activated when you park the machine. Close the switch guard in order to deactivate the switch. When the switch guard is closed, the override switch is placed back into the center neutral position. The override switch should be in the center neutral position during normal operation.

Override Switches

The steel mill arrangement includes three override switches that are located in the cab. These switches are located on the right-hand side of the cab toward the rear of the machine.

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Illustration 3	g01239200
Top view of cab (E) Override switches

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Illustration 4	g01239199
Override switches (F) Switch for the transmission override (G) Auxiliary ignition switch (H) System power switch

System Power Switch

The system power switch (H) should be activated in the forward position if the override feature is needed and the green indicator is not on. If the green indicator is on, leave the switch in the back position.

Note: If this switch needs to be activated contact your local dealer immediately for service. The machine should not be placed back into operation until the dealer has inspected the machine.

Auxiliary Ignition Switch

Your 980H Wheel Loader is equipped with an auxiliary ignition switch (G). This switch should only be used if the standard ignition switch fails. In order to activate, make sure that the green indicator lamp is on. If the lamp is not on, move the system power switch into the activated forward position. When the indicator lamp is on, the auxiliary ignition switch can be put into the momentary forward position in order to start the machine. Hold the switch forward until the machine starts. Once the machine is started, the transmission can be put into first gear forward, neutral, or first gear reverse by using the override switch (F) .

Note: If this switch needs to be activated, contact your local dealer immediately for service. The machine should not be placed back into operation until the dealer has inspected the machine.

Switch for the Transmission Override

Your 980H Wheel Loader comes with a switch (F) for the transmission override. If the transmission does not shift properly with the standard controls, the transmission override can be used. The switch for the transmission override has three positions :FIRST GEAR FORWARD (toggle switch in the forward position), NEUTRAL (toggle switch in the middle position) and FIRST GEAR REVERSE (toggle switch in the back position).

Note: The transmission override should only be used in an emergency situation. During normal operation, the switch for the transmission override should be in the center neutral position.

Note: If this switch needs to be activated, contact your local dealer immediately for service. The machine should not be placed back into operation until the dealer has inspected the machine.

Maintain the machine according to all routine scheduled service. The override functions should be tested on a daily basis. Contact your local dealer for more information.

Override Warning Lights

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Illustration 5	g01324590
View of instrument panel (J) Warning light for the transmission override (K) Warning light for the parking brake override

An illuminated Warning light (J) indicates that the transmission override has lost power from the power supply. The machine should be serviced as soon as possible.

An illuminated Indicator light (K) indicates that the parking brake override has lost power from the power supply. The machine should be removed from the heat until the light turns off. The indicator will also light when the parking brake is engaged.